CA2566661A1

CA2566661A1 - Trailer liner panel

Info

Publication number: CA2566661A1
Application number: CA 2566661
Authority: CA
Inventors: Michael Slywchuk; D'arcy Clifford
Original assignee: Dofasco Inc
Current assignee: ArcelorMittal Dofasco Inc
Priority date: 2006-10-27
Filing date: 2006-10-27
Publication date: 2008-04-27

Abstract

The present invention provides a cargo vehicle interior liner panel formed from a core layer disposed between first and second metal skins.

Description

I I I

TRAILER LINER PANEL
FIELD OF THE INVENTION

[0001] The present invention provides a cargo vehicle liner panel and more particularly a lightweight metal skinned dry van trailer liner panel.

BACKGROUND OF THE INVENTION

[0002] Currently most sheet and post dry van trailers use plywood as an inexpensive material for the inside wall lining. Plywood however needs to be replaced frequently because of its relatively low impact and gouge resistance. Although the initial cost of plywood is low, continuous replacement of the plywood will drive up servicing expenses making long term use an expensive method. Also, since plywood is pre-disposed to moisture pickup and rotting, it may be unsuitable for transportation of consumer goods or foods.

[0003] There are some commercial alternatives available, for example Bulitex and SSL, however these alternatives are costly, heavy, or they may not have good gouge or abrasion resistance.

[0004] It is therefore desirable to provide a lightweight liner panel that has good impact resistance, good abrasion and gouge resistance, is easy to install and has a low manufacturing cost.

SUMMARY OF THE INVENTION

[0005] In one aspect, the present invention provides a lightweight metal skinned liner panel.

[0006] In another aspect, the present invention provides a lightweight metal skinned liner panel having a thickness of less than 0.2 inches.

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BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention will now be described in further detail with reference to the accompanying drawings in which:

[0008] Figure 1 illustrates a sectional side view of one embodiment of the liner panel of the present invention;

[0009] Figure 2 is a top view of a series of liner panels, in accordance with the present invention, joined together;

[0010] Figure 3 is a side view of the liner panels of Figure 2 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The present invention provides a lightweight liner panel indicated generally at numeral 10 in Figure 1.

[0012] The liner panel 10 includes a first metal skin layer 12 and a second metal skin layer 14 having a core layer 16 disposed between them.

[0013] The particular choice of metal for metal skin layers 12 and 14 used in liner panel 10 is not particularly restricted. First metal skin layer 12 and second metal skin layer 14 may be the same or different. Non-limiting examples of suitable metal skin layers for use in the present liner panel include aluminum, cold rolled steel, galvanized steel, tin-coated steel and stainless steel. In a preferred embodiment of the present liner panel, one or both of first metal skin layer 12 and second metal skin layer 14 comprise pre-painted, galvanized, high yield strength steel.

[0014] Preferably, first metal skin layer 12 and second metal skin layer 14 have the same or different thicknesses and the thickness of each is at least 0.010 inches. More preferably, first metal skin layer 12 and second metal skin layer 14 have the same or different thicknesses and the thickness of each is in the range of from about 0.010 inches to about 0.015 inches. Most preferably, first metal skin layer 12 and second metal skin layer 14 have a thickness of 0.012 inches each.

[0015] In one embodiment the core layer 16 may be formed from one or more layers of plastic. The thickness of the final liner panel being equal to or less than 0.2 inches. The plastic may be of any suitable type that may be formed into a thin sheet.
Preferably the plastic is chosen from polyethylene resin or polypropylene resin.

[0016] In an alternative embodiment the core layer 16 may be formed from an extruded composite core of resin and natural fiber. The thickness of the final liner panel being equal to or less than 0.2 inches. More preferably the thickness of the final liner panel is equal to or less than 0.1 inches. Most preferably the thickness of the final liner panel is equal to or less than 0.06 inches.

[0017] In one embodiment the resin in the extruded composite core layer is polyethylene or polypropylene and the fiber is wood flour or other natural fiber such as rice husk.

[0018] In an alternative embodiment the core layer 16 may be formed from three layered resin coated paper sheets. However, varying numbers of sheets may be used depending on the thickness. The thickness of the final liner panel being equal to or less than 0.2 inches. More preferably the thickness of the final liner panel is equal to or less than 0.1 inches. Most preferably the thickness of the final liner panel is equal to or less than 0.06 inches.

[0019] In one embodiment the paper sheets are of saturating kraft paper extrusion coated with polyethylene resin.

[0020] The liner panel of the present invention provides a liner with the desired mechanical and physical properties of a traditional trailer liner, including impact resistance, abrasion and gouge resistance, moisture damage resistance while being low cost to manufacture and being of an appropriate thickness to be used as a liner.

[0021] The liner panel of the present invention may include first and second adhesive layers 18, 20. The first adhesive layer 18 may be disposed between the core layer 16 and the first metal skin layer 12. The second adhesive layer 20 may be disposed between the core layer 16 and the second metal skin layer 14. The adhesive that may be used can be any adhesive that is compatible with the metal skins and the material used to form the core layer.
It will be understood that the inclusion of an adhesive layer is optional and that the liner panel may not require an adhesive layer, for example if the core layer is formed from paper that includes a resin that acts as an adhesive to the metal skins.

[0022] The liner panel of the present invention has increased stiffiiess, increased gouge and abrasion resistance, good impact resistance, is light weight (approx. 1.2 lbs/sq. ft.) and allows for conventional installation. The liner panel of the present invention is also resistant to mold and mildew growth and will not sag or creep like plywood or other plastic panels.

[0023] The current industry standard for gouge resistance is measured using plywood. The liner panel of the present invention has improved gouge resistance compared to the industry standard and provides good stiffness at 0.060".

[0024] The liner panel of the present invention may be sheared or cut and then fastened in place without any requirement for specific tooling providing a liner panel that may be easily installed. The liner panel of the present invention may be used instead of plywood or other alternatives, as an interior liner for the walls, doors, scuff plate, front bulkhead or roof of a cargo vehicle.

[0025] The increased stiffness of the liner panel of the present invention with a lower overall thickness allows for the elimination of a spacer material that is used in conjunction with liner panels acts as an additional stiffener between the outer aluminum skin of the vehicle and the liner panel.

[0026] The liner panel of the present invention is formed by methods known in the art and includes the batch press method, the roll coater method, continuous lamination method or method of direct extrusion between or onto metal skins.

[0027] The following provides an example of the properties of a liner panel produced according to the present invention. The panel included 0.012" steel skins. The flexural stiffness of the panel, based on a 1"x6" sample, was 80 lbs/inch, the tensile modulus was 13.0 x106 psi. The tensile strength of the panel was 49 x106 psi and the nominal weight of the panel was 1.2 lbs/ft2. The total thickness of the panel was 0.055 inches.

[0028] While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments. Further, all of the claims are hereby incorporated by reference into the description of the preferred embodiments.

Claims

1. A liner panel comprising:

a core layer disposed between and bonded to each of a first metal skin layer and a second metal skin layer.

2. The liner panel defined in claim 1, wherein the liner panel further comprises a first adhesive layer interposed between the first metal skin layer and the core layer and a second adhesive layer interposed between the second metal skin layer and the core layer.

3. The liner panel defined in claim 1, wherein the core layer is formed from material selected from the group comprising thermoplastic resin, paper, natural fibers and mixtures thereof.

4. The liner panel defined in claim 1, wherein the core layer is formed from a mixture of resin and natural fibers.

5. The liner panel defined in claim 4, wherein the resin is selected from polyethylene resin, polypropylene resin and mixtures thereof.

6. The liner panel defined in claim 4, wherein the natural fibers is selected from wood flour, rice husks and mixtures thereof.

7. The liner panel defined in claim 1, wherein the liner panel has a thickness of 0.2 inches or less.

8. The liner panel defined in claim 1, wherein the liner panel has a thickness of 0.1 inches or less.

9. The liner panel defined in claim 1, wherein the liner panel has a thickness of 0.06 inches or less.

10. The liner panel defined in claim 1, wherein the first metal skin layer and the second metal skin layer are the same or different, and are formed of a material selected from the group comprising: aluminum, cold rolled steel, galvanized steel, tin-coated steel, and stainless steel.

11. The liner panel defined in claim 1, wherein the first metal skin layer and the second metal skin layer have the same or different thickness and the thickness of each is in the range of from about 0.01 inches to about 0.015 inches.

12. The liner panel defined in claim 11, wherein the first metal skin layer and the second metal skin layer have the same or different thickness and the thickness of each is about 0.012 inches.

13. The liner panel defined in claim 1, wherein the core layer is formed from a plurality of resin coated paper sheets.

14. The use of the liner panel defined in claim 1, as an interior liner panel for at least one of a sidewall, a door, a scuff plate, front bulkhead and a roof of a cargo vehicle.